Materials

Editorial

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8 pages, 223 KiB

Open AccessEditorial

Recent Development in Micromanufacturing of Metallic Materials

by Jingwei Zhao, Zhengyi Jiang, Leszek A. Dobrzański, Chong Soo Lee and Fuxiao Yu

Materials 2020, 13(18), 4046; https://doi.org/10.3390/ma13184046 - 11 Sep 2020

Cited by 4 | Viewed by 2262

Abstract

Product miniaturization is a trend for facilitating product usage, enabling product functions to be implemented in microscale geometries, and aimed at reducing product weight, volume, cost and pollution. Driven by ongoing miniaturization in diverse areas including medical devices, precision equipment, communication devices, micro-electromechanical [...] Read more.

Product miniaturization is a trend for facilitating product usage, enabling product functions to be implemented in microscale geometries, and aimed at reducing product weight, volume, cost and pollution. Driven by ongoing miniaturization in diverse areas including medical devices, precision equipment, communication devices, micro-electromechanical systems (MEMS) and microsystems technology (MST), the demands for micro metallic products have increased tremendously. Such a trend requires development of advanced micromanufacturing technology of metallic materials for producing high-quality micro metallic products that possess excellent dimensional tolerances, required mechanical properties and improved surface quality. Micromanufacturing differs from conventional manufacturing technology in terms of materials, processes, tools, and machines and equipment, due to the miniaturization nature of the whole micromanufacturing system, which challenges the rapid development of micromanufacturing technology. Against such a background, the Special Issue “Micromanufacturing of Metallic Materials” was proposed to present the recent developments of micromanufacturing technologies of metallic materials. The papers collected in the Special Issue include research articles, literature review and technical notes, which have been highlighted in this editorial. Full article

(This article belongs to the Special Issue Micromanufacturing of Metallic Materials)

Research

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27 pages, 12873 KiB

Open AccessArticle

Impact of the Deionized Water on Making High Aspect Ratio Holes in the Inconel 718 Alloy with the Use of Electrical Discharge Drilling

by Magdalena Machno, Rafał Bogucki, Maciej Szkoda and Wojciech Bizoń

Materials 2020, 13(6), 1476; https://doi.org/10.3390/ma13061476 - 24 Mar 2020

Cited by 18 | Viewed by 3419

Abstract

Nickel-based superalloys are being increasingly applied to manufacture components in the aviation industry. The materials are classified as difficult-to-machine using conventional methods. Nowadays, manufacturing techniques are needed to drill high aspect ratio holes of above 20:1 (depth-to-diameter ratio) in these materials. One of [...] Read more.

Nickel-based superalloys are being increasingly applied to manufacture components in the aviation industry. The materials are classified as difficult-to-machine using conventional methods. Nowadays, manufacturing techniques are needed to drill high aspect ratio holes of above 20:1 (depth-to-diameter ratio) in these materials. One of the most effective methods of making high-aspect-ratio holes is electrical discharge drilling (EDD). While drilling high aspect ratio holes, a crucial issue is the flushing of the gap area and the evacuation of the erosion products. The use of deionized water as the dielectric fluid in the EDD offers a considerable potential. This paper includes an analysis of the influence of the machining parameters (pulse time, current amplitude and discharge voltage) on the process performance (drilling speed, linear tool wear, taper angle, hole’s aspect ratio, side gap thickness), during the EDD with the use of deionized water in the Inconel 718 alloy. The obtained through holes were subjected to the extended analysis. The impact of the initial working fluid temperature and pressure on the conditions of the flow through the electrode channel was also subjected to the analysis. The deionized water properties were changed by applying an initial temperature. Based on the results of an analysis of the previous research, the EDD of the through holes was performed for a pre-set initial temperature (~313.15 °K) and initial pressure of the working fluid (8 MPa) and selected process parameters. An analysis of the results indicates increasing of hole’s aspect ratio by about 15% (above 30), decreasing the side gap thickness by about 40% and enhanced surface integrity. Full article

(This article belongs to the Special Issue Micromanufacturing of Metallic Materials)

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13 pages, 3822 KiB

Open AccessArticle

Enhancing the Surface Quality of Micro Titanium Alloy Specimen in WEDM Process by Adopting TGRA-Based Optimization

by Muthuramalingam Thangaraj, Ramamurthy Annamalai, Khaja Moiduddin, Mohammed Alkindi, Sundar Ramalingam and Osama Alghamdi

Materials 2020, 13(6), 1440; https://doi.org/10.3390/ma13061440 - 21 Mar 2020

Cited by 56 | Viewed by 3464

Abstract

The surface measures of machined titanium alloys as dental materials can be enhanced by adopting a decision-making algorithm in the machining process. The surface quality is normally characterized by more than one quality parameter. Hence, it is very important to establish multi-criteria decision [...] Read more.

The surface measures of machined titanium alloys as dental materials can be enhanced by adopting a decision-making algorithm in the machining process. The surface quality is normally characterized by more than one quality parameter. Hence, it is very important to establish multi-criteria decision making to compute the optimal process factors. In the present study, Taguchi–Grey analysis-based criteria decision making has been applied to the input process factors in the wire EDM (electric discharge machining) process. The recast layer thickness, wire wear ratio and micro hardness have been chosen to evaluate the quality measures. It was found that the wire electrode selection was the most influential factor on the quality measures in the WEDM process, due to its significance in creating spark energy. The optimal arrangement of the input process parameters has been found using the proposed approach as gap voltage (70 V), discharge current (15 A) and duty factor (0.6). It was proved that the proposed method can enhance the efficacy of the process. Utilizing the computed combination of optimal process parameters in surface quality analysis has significantly contributed to improving the quality of machining surface. Full article

(This article belongs to the Special Issue Micromanufacturing of Metallic Materials)

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12 pages, 5473 KiB

Open AccessArticle

Optimum Clearance in the Microblanking of Thin Foil of Austenitic Stainless Steel JIS SUS304 Studied from Shear Cut Surface and Punch Load

by Yohei Suzuki, Ming Yang and Masao Murakawa

Materials 2020, 13(3), 678; https://doi.org/10.3390/ma13030678 - 3 Feb 2020

Cited by 10 | Viewed by 3412

Abstract

An extrusion-type fine blanking with a negative clearance was proposed by the authors instead of standard fine blanking for creating a full-sheared surface in the micro blanking process. In this study, micro blanking experiments and finite element analyses with narrow, zero and negative [...] Read more.

An extrusion-type fine blanking with a negative clearance was proposed by the authors instead of standard fine blanking for creating a full-sheared surface in the micro blanking process. In this study, micro blanking experiments and finite element analyses with narrow, zero and negative clearances are carried out for the optimizing the clearance at which a shear cut surface can be finished with a full-sheared surface with the minimized punch load. Fracture criterion, hydrostatic stress and maximum punch stress for the conditions with various clearances are investigated. As a result, it was clarified that the clearance at which the cut surface does not fracture and minimization of the punch load is achieved is gained by the use of clearance −4 μm. Full article

(This article belongs to the Special Issue Micromanufacturing of Metallic Materials)

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13 pages, 4772 KiB

Open AccessArticle

Investigation on Microsheet Metal Deformation Behaviors in Ultrasonic-Vibration-Assisted Uniaxial Tension with Aluminum Alloy 5052

by Chunju Wang, Weiwei Zhang, Lidong Cheng, Changqiong Zhu, Xinwei Wang, Haibo Han, Haidong He and Risheng Hua

Materials 2020, 13(3), 637; https://doi.org/10.3390/ma13030637 - 31 Jan 2020

Cited by 11 | Viewed by 2639

Abstract

Ultrasonic vibration (UV) is widely used in the forming, joining, machining process, etc. for the acoustic softening effect. For parts with small dimensions, UV with limited output energy is very suitable for the microforming process and has been gaininf more and more attention. [...] Read more.

Ultrasonic vibration (UV) is widely used in the forming, joining, machining process, etc. for the acoustic softening effect. For parts with small dimensions, UV with limited output energy is very suitable for the microforming process and has been gaininf more and more attention. In this investigation, UV-assisted uniaxial tensile experiments were carried out utilizing GB 5052 thin sheets of different thicknesses and grain sizes, respectively. The coupling effects of UV and the specimen dimension on the properties of the material were analyzed from the viewpoint of acoustic energy in activating dislocations. A reduction of flow stress was found for the existing acoustic softening effects of UV. Additionally, the residual effects of UV were demonstrated when UV was turned off. The uniform deformation ability of thin sheet could be improved by increasing the hardening exponent with UV. The experimental results indicate that UV is very helpful in improving the forming limit in microsheet forming, e.g., microbulging and deep drawing processes. Full article

(This article belongs to the Special Issue Micromanufacturing of Metallic Materials)

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10 pages, 6359 KiB

Open AccessArticle

Bio-Inspired Functional Surface Fabricated by Electrically Assisted Micro-Embossing of AZ31 Magnesium Alloy

by Xinwei Wang, Jie Xu, Chunju Wang, Antonio J. Sánchez Egea, Jianwei Li, Chen Liu, Zhenlong Wang, Tiejun Zhang, Bin Guo and Jian Cao

Materials 2020, 13(2), 412; https://doi.org/10.3390/ma13020412 - 16 Jan 2020

Cited by 14 | Viewed by 2869

Abstract

Developing bio-inspired functional surfaces on engineering metals is of extreme importance, involving different industrial sectors, like automotive or aeronautics. In particular, micro-embossing is one of the efficient and large-scale processes for manufacturing bio-inspired textures on metallic surfaces. However, this process faces some problems, [...] Read more.

Developing bio-inspired functional surfaces on engineering metals is of extreme importance, involving different industrial sectors, like automotive or aeronautics. In particular, micro-embossing is one of the efficient and large-scale processes for manufacturing bio-inspired textures on metallic surfaces. However, this process faces some problems, such as filling defects and die breakage due to size effect, which restrict this technology for some components. Electrically assisted micro-forming has demonstrated the ability of reducing size effects, improving formability and decreasing flow stress, making it a promising hybrid process to control the filling quality of micro-scale features. This research focuses on the use of different current densities to perform embossed micro-channels of 7 μm and sharklet patterns of 10 μm in textured bulk metallic glass dies. These dies are prepared by thermoplastic forming based on the compression of photolithographic silicon molds. The results show that large areas of bio-inspired textures could be fabricated on magnesium alloy when current densities higher than 6 A/mm² (threshold) are used. The optimal surface quality scenario is obtained for a current density of 13 A/mm². Additionally, filling depth and depth–width ratio nonlinearly increases when higher current densities are used, where the temperature is a key parameter to control, keeping it below the temperature of the glass transition to avoid melting or an early breakage of the die. Full article

(This article belongs to the Special Issue Micromanufacturing of Metallic Materials)

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12 pages, 5129 KiB

Open AccessArticle

Investigation of Electrically-Assisted Rolling Process of Corrugated Surface Microstructure with T2 Copper Foil

by Shaoxi Xue, Chunju Wang, Pengyu Chen, Zhenhai Xu, Lidong Cheng, Bin Guo and Debin Shan

Materials 2019, 12(24), 4144; https://doi.org/10.3390/ma12244144 - 11 Dec 2019

Cited by 12 | Viewed by 2444

Abstract

Electrically-assisted (EA) forming is a low-cost and high-efficiency method to enhance the formability of materials. In the study, EAF tensile tests are carried out to study the properties of T2 copper foil in an annealed state, and the effect of the electric current [...] Read more.

Electrically-assisted (EA) forming is a low-cost and high-efficiency method to enhance the formability of materials. In the study, EAF tensile tests are carried out to study the properties of T2 copper foil in an annealed state, and the effect of the electric current on the forming quality of corrugated foils is further studied in the EA rolling forming process. The result shows that the current reduces the flow stress and the fracture strain, which is different from the result of rolled samples. The joule heating effect on mechanical properties is significant in EA tension, and the softening effect of the surface layer can be observed at tensile strength, due to the grain size effect. Moreover, the current can weaken the grain size effect. In the rolling forming process, the influence of different electrical parameters on the forming height is remarkable, especially for the rolled T2 copper. The appropriate electrical parameters can improve the forming height, while keeping a small thickness thinning. Nevertheless, the high current density will lead to local rupture. This study proves that the current can improve the forming quality of the corrugated foils and is a promising surface texture forming process. Full article

(This article belongs to the Special Issue Micromanufacturing of Metallic Materials)

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10 pages, 16166 KiB

Open AccessArticle

Fabrication of Micro-Punch Array by Plasma Printing for Micro-Embossing into Copper Substrates

by Tomomi Shiratori, Tatsuhiko Aizawa, Yasuo Saito and Kuniaki Dohda

Materials 2019, 12(16), 2640; https://doi.org/10.3390/ma12162640 - 19 Aug 2019

Cited by 4 | Viewed by 2986

Abstract

Copper substrates were wrought to have micro-grooves for packaging by micro-stamping with use of a AISI316 stainless steel micro-punch array. The micro-texture of this arrayed punch was first tailored and compiled into CAD data. A screen film was prepared to have the tailored [...] Read more.

Copper substrates were wrought to have micro-grooves for packaging by micro-stamping with use of a AISI316 stainless steel micro-punch array. The micro-texture of this arrayed punch was first tailored and compiled into CAD data. A screen film was prepared to have the tailored micro-pattern in correspondence to the CAD data. A negative pattern to this screen was printed directly onto the AISI316 die substrate. This substrate was plasma nitrided at 673 K for 14.4 ks. The unprinted die surfaces were selectively nitrogen super-saturated to have sufficiently high corrosion toughness and hardness; other surfaces were masked by the prints. The two-dimensional micro-pattern on the screen was transformed into a three-dimensional nitrogen supersaturated micro-texture embedded in the AISI316 die. The printed surfaces were selectively sand-blasted to fabricate the micro-textured punch array for micro-embossing. A uniaxial compression testing machine was utilized to describe the micro-embossing behavior in copper substrates and to investigate how the micro-texture on the die was transcribed to the copper. The micro-punch array in this study consisted of three closed loop heads with a width of 75 µm and a height of 120 µm after plasma nitriding and sand-blasting. Since the nitrogen supersaturated heads had sufficient hardness against the blasting media, the printed parts of AISI316 die were removed. The micro-embossing process was described by comparison of the geometric configurations between the multi-punch array and the embossed copper plate. Full article

(This article belongs to the Special Issue Micromanufacturing of Metallic Materials)

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10 pages, 4726 KiB

Open AccessArticle

Elucidation of Shearing Mechanism of Finish-type FB and Extrusion-type FB for Thin Foil of JIS SUS304 by Numerical and EBSD Analyses

by Yohei Suzuki, Tomomi Shiratori, Ming Yang and Masao Murakawa

Materials 2019, 12(13), 2143; https://doi.org/10.3390/ma12132143 - 3 Jul 2019

Cited by 6 | Viewed by 2806

Abstract

A numerical analysis using FE (finite element) analysis was performed to clarify the shearing mechanism in the process of extrusion-type fine blanking (FB) for a thin foil of JIS SUS304 in this study. Extrusion-type FB, in which a negative clearance between the punch [...] Read more.

A numerical analysis using FE (finite element) analysis was performed to clarify the shearing mechanism in the process of extrusion-type fine blanking (FB) for a thin foil of JIS SUS304 in this study. Extrusion-type FB, in which a negative clearance between the punch and the die has been developed and investigated experimentally to improve the quality of the sheared surface in the blanking of thin foils. The resultant sheared surface for extrusion-type FB indicated an almost completely sheared surface, and the fracture portion on the sheared surface was much smaller than that in conventional FB, the so-called finish-type FB. The material flow and fracture criteria in extrusion-type FB were analyzed in comparison with those in finish-type FB. The differences in material flow and so-called critical fracture value were verified for the two processes. The principal stress near the shearing surface has mostly compressive components in extrusion-type FB due to its negative clearance, and the critical fracture value was also less than that in finish-type FB, in which the principal stress near the shearing surface has mostly tensile components. Furthermore, SEM observation with EBSD (electron back-scatter diffraction) analysis of the shearing surface was performed to verify the phenomena. Reductions in deformation-induced crystal orientation rotation and martensite transformation in extrusion-type FB were confirmed in comparison with those in finish-type FB from the analysis results. Full article

(This article belongs to the Special Issue Micromanufacturing of Metallic Materials)

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13 pages, 8245 KiB

Open AccessArticle

A Numerical Study of Slip System Evolution in Ultra-Thin Stainless Steel Foil

by Zhongkai Ren, Wanwan Fan, Jie Hou and Tao Wang

Materials 2019, 12(11), 1819; https://doi.org/10.3390/ma12111819 - 5 Jun 2019

Cited by 15 | Viewed by 5122

Abstract

In order to quantitatively describe the effect of the initial grain orientation on the inhomogeneous deformation of 304 austenitic stainless steel foil during tension, a three-dimensional uniaxial tension model was established, based on the crystal plasticity finite element method (CPFEM) and Voronoi polyhedron [...] Read more.

In order to quantitatively describe the effect of the initial grain orientation on the inhomogeneous deformation of 304 austenitic stainless steel foil during tension, a three-dimensional uniaxial tension model was established, based on the crystal plasticity finite element method (CPFEM) and Voronoi polyhedron theory. A three-dimensional representative volume element (RVE) was used to simulate the slip deformation of 304 stainless steel foil with five typical grain orientations under the same engineering strain. The simulation results show that the number and characteristics of active slip systems and the deformation degree of the grain are different due to the different initial grain orientations. The slip systems preferentially initiate at grain boundaries and cause slip system activity at the interior and free surface of the grain. The Brass, S, and Copper oriented 304 stainless steel foil exhibits a high strain hardening index, which is beneficial to strengthening. However, the Cube and Goss oriented 304 stainless steel foil has a low deformation resistance and is prone to plastic deformation. Full article

(This article belongs to the Special Issue Micromanufacturing of Metallic Materials)

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15 pages, 4810 KiB

Open AccessArticle

Adaptive Spiral Tool Path Generation for Diamond Turning of Large Aperture Freeform Optics

by Dongfang Wang, Yongxin Sui, Huaijiang Yang and Duo Li

Materials 2019, 12(5), 810; https://doi.org/10.3390/ma12050810 - 8 Mar 2019

Cited by 11 | Viewed by 4759

Abstract

Slow tool servo (STS) diamond turning is a well-developed technique for freeform optics machining. Due to low machining efficiency, fluctuations in side-feeding motion and redundant control points for large aperture optics, this paper reports a novel adaptive tool path generation (ATPG) for STS [...] Read more.

Slow tool servo (STS) diamond turning is a well-developed technique for freeform optics machining. Due to low machining efficiency, fluctuations in side-feeding motion and redundant control points for large aperture optics, this paper reports a novel adaptive tool path generation (ATPG) for STS diamond turning. In ATPG, the sampling intervals both in feeding and cutting direction are independently controlled according to interpolation error and cutting residual tolerance. A smooth curve is approximated to the side-feeding motion for reducing the fluctuations in feeding direction. Comparison of surface generation of typical freeform surfaces with ATPG and commercial software DiffSys is conducted both theoretically and experimentally. The result demonstrates that the ATPG can effectively reduce the volume of control points, decrease the vibration of side-feeding motion and improve machining efficiency while surface quality is well maintained for large aperture freeform optics. Full article

(This article belongs to the Special Issue Micromanufacturing of Metallic Materials)

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14 pages, 5024 KiB

Open AccessArticle

Ultrasonic Vibration Facilitates the Micro-Formability of a Zr-Based Metallic Glass

by Guangchao Han, Zhuo Peng, Linhong Xu and Ning Li

Materials 2018, 11(12), 2568; https://doi.org/10.3390/ma11122568 - 17 Dec 2018

Cited by 15 | Viewed by 3646

Abstract

Thermoplastic microforming not only breaks through the bottleneck in the manufacture of metallic glasses, but also offers alluring prospects in microengineering applications. The microformability of metallic glasses decreases with a reduction in the mold size owing to the interfacial size effect, which seriously [...] Read more.

Thermoplastic microforming not only breaks through the bottleneck in the manufacture of metallic glasses, but also offers alluring prospects in microengineering applications. The microformability of metallic glasses decreases with a reduction in the mold size owing to the interfacial size effect, which seriously hinders their large-scale applications. Here, ultrasonic vibration was introduced as an effective method to improve the microformability of metallic glasses, owing to its capabilities of improving the material flow and reducing the interfacial friction. The results reveal that the microformability of supercooled Zr₃₅Ti₃₀Cu_8.25Be_26.75 metallic glasses is conspicuously enhanced by comparison with those under quasi-static loading. The more intriguing finding is that the microformability of the Zr-based metallic glasses can be further improved by tuning the amplitude of the ultrasonic vibration. The physical origin of the above scenario is understood, in depth, on the basis of ultrasonic vibration-assisted material flow, as demonstrated by the finite element method. Full article

(This article belongs to the Special Issue Micromanufacturing of Metallic Materials)

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11 pages, 3634 KiB

Open AccessArticle

Micro-Tensile Behavior of Mg-Al-Zn Alloy Processed by Equal Channel Angular Pressing (ECAP)

by Kristián Máthis, Michal Köver, Jitka Stráská, Zuzanka Trojanová, Ján Džugan and Kristýna Halmešová

Materials 2018, 11(9), 1644; https://doi.org/10.3390/ma11091644 - 7 Sep 2018

Cited by 24 | Viewed by 3449

Abstract

Commercially available AZ31 magnesium alloy was four times extruded in an equal rectangular channel using three different routes (A, B, and C). Micro tensile deformation tests were performed at room temperature with the aim to reveal any plastic anisotropy developed during the extrusion. [...] Read more.

Commercially available AZ31 magnesium alloy was four times extruded in an equal rectangular channel using three different routes (A, B, and C). Micro tensile deformation tests were performed at room temperature with the aim to reveal any plastic anisotropy developed during the extrusion. Samples for micro tensile experiments were cut from extruded billets in different orientations with respect to the pressing direction. Information about the microstructure of samples was obtained using the electron back-scatter diffraction (EBSD) technique. Deformation characteristics (yield stress, ultimate tensile stress and uniform elongation) exhibited significant anisotropy as a consequence of different orientations between the stress direction and texture and thus different deformation mechanisms. Full article

(This article belongs to the Special Issue Micromanufacturing of Metallic Materials)

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Review

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38 pages, 17310 KiB

Open AccessReview

On Residual Stress Development, Prevention, and Compensation in Metal Additive Manufacturing

by Kevin Carpenter and Ali Tabei

Materials 2020, 13(2), 255; https://doi.org/10.3390/ma13020255 - 7 Jan 2020

Cited by 89 | Viewed by 8944

Abstract

One of the most appealing qualities of additive manufacturing (AM) is the ability to produce complex geometries faster than most traditional methods. The trade-off for this advantage is that AM parts are extremely vulnerable to residual stresses (RSs), which may lead to geometrical [...] Read more.

One of the most appealing qualities of additive manufacturing (AM) is the ability to produce complex geometries faster than most traditional methods. The trade-off for this advantage is that AM parts are extremely vulnerable to residual stresses (RSs), which may lead to geometrical distortions and quality inspection failures. Additionally, tensile RSs negatively impact the fatigue life and other mechanical performance characteristics of the parts in service. Therefore, in order for AM to cross the borders of prototyping toward a viable manufacturing process, the major challenge of RS development must be addressed. Different AM technologies contain many unique features and parameters, which influence the temperature gradients in the part and lead to development of RSs. The stresses formed in AM parts are typically observed to be compressive in the center of the part and tensile on the top layers. To mitigate these stresses, process parameters must be optimized, which requires exhaustive and costly experimentations. Alternative to experiments, holistic computational frameworks which can capture much of the physics while balancing computational costs are introduced for rapid and inexpensive investigation into development and prevention of RSs in AM. In this review, the focus is on metal additive manufacturing, referred to simply as “AM”, and, after a brief introduction to various AM technologies and thermoelastic mechanics, prior works on sources of RSs in AM are discussed. Furthermore, the state-of-the-art knowledge on RS measurement techniques, the influence of AM process parameters, current modeling approaches, and distortion prevention approaches are reported. Full article

(This article belongs to the Special Issue Micromanufacturing of Metallic Materials)

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Other

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14 pages, 7019 KiB

Open AccessTechnical Note

Experimental Investigation on Form Error for Slow Tool Servo Diamond Turning of Micro Lens Arrays on the Roller Mold

by Yutao Liu, Zheng Qiao, Da Qu, Yangong Wu, Jiadai Xue, Duo Li and Bo Wang

Materials 2018, 11(10), 1816; https://doi.org/10.3390/ma11101816 - 25 Sep 2018

Cited by 21 | Viewed by 3635

Abstract

Slow tool servo (STS) assisted ultra-precision diamond turning is considered as a promising machining process with high accuracy and low cost to generate the large-area micro lens arrays (MLAs) on the roller mold. However, the chatter mark is obvious at the cut-in part [...] Read more.

Slow tool servo (STS) assisted ultra-precision diamond turning is considered as a promising machining process with high accuracy and low cost to generate the large-area micro lens arrays (MLAs) on the roller mold. However, the chatter mark is obvious at the cut-in part of every machined micro lens along the cutting direction, which is a common problem for the generation of MLAs using STS. In this study, a novel forming approach based on STS is presented to fabricate MLAs on the aluminum alloy (6061) roller mold, which is a high-efficiency machining approach in comparison to a traditional method based on STS. Based on the different distribution patterns of the discrete point of micro lens, the equal-arc method and the equal-angle method are also proposed to generate the tool path. According to a kinematic analysis of the cutting axis, the chatter mark results from the overlarge instantaneous acceleration oscillations of the cutting axis during STS diamond turning process of MLAs. Cutting parameters including the number of discrete points and cutting time of every discrete point have been experimentally investigated to reduce the chatter mark. Finally, typical MLAs (20.52-μm height and 700-μm aperture) is successfully machined with the optimal cutting parameters. The results are acquired with a fine surface quality, i.e., form error of micro lenses is 0.632 μm, which validate the feasibility of the new machining method. Full article

(This article belongs to the Special Issue Micromanufacturing of Metallic Materials)

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